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Introduction Guide To Vibration Monitoring: Measurements, Analysis, and Terminology
Introduction Guide To Vibration Monitoring: Measurements, Analysis, and Terminology
Monitoring
Measurements, Analysis, and Terminology
Summary
This guide introduces machinery maintenance workers to
condition monitoring analysis methods used to detect and
analyze machine component failures. This guide does not intend
to make the reader an analysis expert. It merely informs the
reader about common analysis methods and lays the foundation
for understanding machinery analysis concepts. Moreover, it tells
the reader what is needed to perform an actual analysis on
specific machinery.
JM02001
Jason Mais & Scott Brady
30 pages
May 2002
SKF Reliability Systems
@ptitudeXchange
5271 Viewridge Court
San Diego, CA 92123
United States
tel. +1 858 496 3554
fax +1 858 496 3555
email: info@aptitudexchange.com
Internet: www.aptitudexchange.com
Introduction
This guide introduces machinery
maintenance workers to condition
monitoring analysis methods used to detect
and analyze machine component failures.
This guide does not intend to make the
reader an analysis expert. It merely informs
the reader about common analysis methods
and lays the foundation for understanding
machinery analysis concepts. Moreover, it
tells the reader what is needed to perform an
actual analysis on specific machinery.
Rule 1: Know what you do and do not
know!
Often, a situation arises where the answer is
not contained within analysis data. At this
point, I dont know is the best answer. A
wrong diagnosis can be costly and can
rapidly diminish a machinery maintenance
workers credibility. Thus, a vibration
specialist is required to analyze the problem.
Detection vs. Analysis
The differences between detecting a
machinery problem and analyzing the cause
of a machinery problem are vast. Replacing
a new bearing with one that indicates a high
level of vibration may or may not be the
solution to bearing failure. Usually, a
secondary issue developed in the machine
and is attributing to premature bearing
failure. To solve the problem, you must find
the attributing factor or cause of the bearing
failure (i.e. misalignment, looseness,
imbalance). This process is referred to as
finding the root cause of the failure. If this
important step is not followed, you simply
replace the bearing without developing a
condition monitoring program. It is essential
to detect machinery problems early enough
to plan repair actions and minimize
downtime.
Phase
Enveloping or Demodulation
Peak = 1.0
Peak-to-Peak = 2 x Peak
Pressure:
Figure 2. Standard Position Measurements.
Manufactured differently
Maintained differently
Vibration Measurements
Methods
Figure 6. A Dial Gage (Left) Measures Displacement. A Common Displacement Probe (Right).
Velocity
Velocity measurements are taken in in/sec or
mm/sec. Velocity is the measure of a
signals rate of change in displacement. It is
the most common machine vibration
measurement. Historically, the velocity
sensor was one of the first electrical sensors
used for machine condition monitoring. This
is due in part to the resultant of an equal
amount of generated dynamic motion;
velocity remains constant regardless of
frequency. However, at low frequencies
(under 10 Hz) or high frequencies (above 2
kHz), velocity sensors lose their
effectiveness.
Figure 7. Accelerometer.
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11
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Figure 11. Enveloped and Time Waveform Spectrum With Outer Race Defect. Envelope Detection Filters Out Low
Frequency Rotational Signals and Enhances the Bearings Repetitive Impact Type Signals to Focus on Repetitive
Events in the Bearing Defect Frequency Range. (For Example, Repetitive Bearing and Gear-Tooth Vibration
Signals.)
Spall
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International Standards
Vibration Diagnostic Tables
The following sections contain agreed upon
International Standards as they relate to
vibration monitoring. These standards are a
basis for developing a condition monitoring
program. However, they are to be used in
conjunction with manufacturer suggested
acceptability levels for specific machines
and industries. Many of the industry or
machine type standards can also be obtained
through condition monitoring or vibration
monitoring companies.
Excessive
Excessive
Excessive
Horizontal
Vertical
Axial
Structural
Vibration
Indicates:
Vibration
Indicates:
Vibration
Indicates:
Vibration
Indicates:
Imbalance
YES
NO
YES
NO
Misalignment
YES
NO
YES
NO
Looseness
YES
YES
NO
YES
Vertical
Electrical
Faults
Measured
as Vibration
Notes
Horizontal
To detect an electrical
problem:
Turn off machine
power and monitor
vibration. If the
vibration immediately
drops, the problem is
electrical.
Note: YES = ISO 2372
Unsatisfactory Unacceptable Levels.
NO = ISO 2372
Good Satisfactory Levels.
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Excessive
Excessive
Excessive
Horizontal
Vertical
Axial
Structural
Vibration
Indicates:
Vibration
Indicates:
Vibration
Indicates:
Vibration
Indicates:
Imbalance
YES
NO
NO
NO
Misalignment
YES
NO
YES
NO
Looseness
YES
NO
NO
YES
Electrical
Faults
Measured
as Vibration
Notes
To detect an electrical
problem:
Turn off machine
power and monitor
vibration. If the
vibration immediately
drops, the problem is
electrical.
Note: YES = ISO 2372
Unsatisfactory Unacceptable Levels.
NO = ISO 2372
Good Satisfactory Levels.
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Detection
Units
Dominant
Frequencies
Phase Relationship
(Note: phase ref. within 30 degrees)
Comments
IMBALANCE
Mass
Radial
Acceleration /
Velocity /
Displacement
Overhung
Mass
Axial and
Radial
Acceleration /
Velocity /
Displacement
Bent Shaft
Axial and
Radial
Acceleration /
Velocity /
Displacement
1x
1x
1x
MISALIGNMENT
Angular
Axial
Acceleration /
Velocity /
Displacement
1x and 2x
Parallel
Radial
Acceleration /
Velocity /
Displacement
1x and 2x
Combination
of Angular
and Parallel
Axial and
Radial
Acceleration /
Velocity /
Displacement
1x and 2x
With severe
misalignment, the
spectrum may
contain multiple
harmonics from 3x
to 10x running
speed. If vibration
amplitude in the
horizontal plane is
increased 2 or 3
times, then
misalignment is
again indicated.
(Account for
change in sensor
orientation when
making axial
measurements)
MECHANICAL LOOSENESS
Wear / Fitting
Axial and
Radial
Acceleration /
Velocity /
Displacement
1x, 2x,
3x10x
Vibration
amplitudes may
vary significantly
as the sensor is
placed in differing
locations around
the bearing.
(Account for
change in sensor
orientation when
making axial
measurements)
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Detection
Units
Dominant
Frequencies
Phase Relationship
(Note: phase ref. within 30 degrees)
Comments
Race Defect
Radial
Acceleration /
Enveloping
4x15x
No correlation.
With acceleration
measurements,
bearing defect
frequencies appear
as a wide bump
in the spectrum.
Bearing defect
frequencies are
non-integer
multiples of
running speed (i.e.,
4.32 x running
speed)
No correlation.
The exact
frequency relates
to the number of
teeth each gear
contains times the
rotational speed
(running speed) to
which the gear is
attached.
GEAR DEFECTS
Gear Mesh
Radial
Acceleration /
Enveloping
20x200x
DC Motors
Radial
Radial
Acceleration /
Velocity /
Displacement
Acceleration /
Velocity /
Displacement
Line
Frequency
No correlation.
Defect
Frequencies can
be seen at
exactly twice the
line frequency.
No correlation.
DC Motor
problems due to
broken fields
windings, bad
SCRs or loose
connections are
reflected as
higher
amplitudes at the
SCR frequencies
SCR
Frequency
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Conclusion
This guide simply provides an introduction
to the field of vibration monitoring and
diagnosis. A few references are suggested
for more information and related
@ptitudeXchange documents.
Further Reading
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